Method of molding and assembling structural

ABSTRACT

Mobile structural unit molding and assembling apparatus includes a support portion, a raw material supplying portion, a molding portion, a unit transferring portion and a control portion. The support portion includes at least one base section with a wheeled carriage. The raw material supplying portion includes a plurality of reservoirs disposed on the base section. The molding portion includes at least one rotatable mold assembly disposed on the base section including at least two separable mold sections. A mixing chamber adjacent the mold assembly connects with raw material reservoirs through independent conduits. The unit transferring portion includes a tiltable unit positioning assembly selectively movable with respect to the molding portion. The control portion includes a programmable memory, a coordinator, sensors, actuators, a unit orienter and circuitry therefor. A continuous structural unit molding and assembling method includes the steps of flowing a freshly formed resin forming mixture over all surfaces of a mold cavity by multiaxis rotation to form a structural unit, conveying the unit not fully cured, orienting the unit in an inclined orientation, and assembling it with previously positioned units, and the resulting structure.

Cross-References to Related Applications

This application is a continuation-in-part of pending application Ser.No. 495,621, filed Mar. 19, 1990, now U.S. Pat. No. 5,011,636 which inturn is a continuation-in-part of application Ser. No. 271,717, filedNov. 16, 1988, now U.S. Pat. No. 4,909,718. This application also is acontinuation-in-part of pending application Ser. No. 417,502, filed Oct.5, 1989, now U.S. Pat. No. 5,022,838 which in turn is acontinuation-in-part of application Ser. No. 271,686, filed Nov. 16,1988, now U.S. Pat. No. 4,956,133. Both Serial Nos. 271,717 and 271,686in turn are continuations-in-part of application Ser. No. 202,267, filedJun. 6, 1988, now U.S. Pat. No. 4,956,135, which in turn is acontinuation-in-part of application Ser. No. 890,742, filed Jul. 30,1986, now U.S. Pat. No. 4,749,533, which is a division of applicationSer. No. 766,498, filed Aug. 19, 1985, now U.S. Pat. No. 4,671,753.

Background of the Invention

This invention relates to a novel apparatus and new method for moldingand assembling units to form structures.

Throughout history, an important activity has been the construction ofbuildings for various purposes such as dwellings, storage and the like.With primitive societies, it was common to construct such buildings fromnatural materials that were readily available. In forested areas,structures were erected with logs or boards that had been cut from thelogs.

Where trees were less common, people used stone for building materialsor artificial adobe substitutes formed from mud baked in the sun. Tomake artificial stones or bricks more durable and less likely tocrumble, it was customary to mix straw or similar materials with themud. The building components ordinarily were fabricated and/or preparedat the building site.

Even today, most building construction is performed at the building siteusing components and materials trucked to the site from other locations.These building methods require that a large number of differentcraftsmen do their work at the construction site. Thus, the quality ofthe finished building depends upon the ability of the craftsmen toperform their tasks properly under the conditions and distractionsgenerated by the activities of the many other workmen on the site at thesame time.

Efforts have been directed to the use of prefabricated modules producedat central locations and trucked to the building site for assembly.However, this type of construction has gained only limited acceptancebecause of the lack of flexibility in building designs, the module sizelimitations and the high cost of transporting modules over the highways.

To overcome the shortcomings of traditional construction procedures, therenowned architect, Frank Lloyd Wright and his associates, more than ahalf century ago, pioneered Usonian block houses fabricated with casthollow concrete blocks. The blocks are formed with grooves around theiredges so they can be interconnected with mortar and steel reinforcingbars like giant children's building blocks. The interconnected blockscan be used to span openings, contain utility services, accommodateglass, doors and the like. This system enables an owner and/or smallcrew to construct a building without an army of special craftsmen suchas masons, carpenters, etc.

The blocks can be fabricated at the building site in simple molds. Theblock system is based on modular units generally two to four feet inwidth. Great care must be exercised in the assembly of the blocks toensure that the joints follow the module dimensions. Any cumulativeincremental error eventually may disrupt the modular structure. Thus,the dimensions of the individual blocks have to be maintained withinvery close tolerances which is difficult to achieve with the inherentshrinkage that occurs during the molding of the blocks and the curingthereof with time.

From a practical viewpoint, the collection of a sufficiently largenumber of blocks of exactly the same dimensions for an entire buildingincluding the roof, walls, floors and partitions is a formidable task.One must be willing to make a much larger number of blocks than neededand then inspect each carefully, discarding the many blocks that do notmeet specifications.

Even when tolerable dimensional reproducability is achieved, the highstrength and structural uniformity required for building quality,durability and integrity still must be maintained.

Earlier U.S. patent application Ser. Nos. 271,717 and 495,621 above aredirected to novel structural units which have a high level of strengthand uniformity of size that meet dimensional and structuralspecifications easily. The units also include peripheral edges which canbe interlocked to facilitate assembly. The structural integrity ofbuildings erected from such units however will depend to a considerableextent upon the care, skill and experience of the persons assembling theunits.

SUMMARY OF THE INVENTION

The present invention provides a novel mobile apparatus and method whichcombines the molding and assembly of structural units into an integratedoperation. Moreover, the molding and assembly are performedautomatically with a minimum of hand labor. Furthermore, the apparatusand method of the invention provide a high degree of design flexibilityas well as construction efficiencies.

The molding and assembling apparatus of the present invention isrelatively simple in design and can be produced at moderate cost.Commercially available materials and components can be utilized in itsconstruction. Also, conventional metal fabricating techniques andprocedures can be employed in the manufacture of the apparatus.

The molding and assembling apparatus and method of the invention can beadapted to mold and assemble a wide variety of different structuralunits. Thus, foundation units, wall units, window units, corner units,floor units, ceiling units, roof units, solar units and the like can bemolded and assembled successfully with the method and apparatus of theinvention.

Variations in configuration, function, structure, composition, etc. canbe attained simply and quickly with the method and apparatus of theinvention. Even with such variations, uniformity of dimensions,composition and quality can be maintained without difficulty.

Structural units can be molded and assembled to form buildings and otherstructures of many different designs rapidly and with precision. Theapparatus and method of the invention enable the structural units to bemolded and assembled in modules precisely without mortar and withoutcontinuous checking of alignment and orientation as each unit is added.Subsequent modification or alteration of a building can be made ifdesired.

BRIEF DESCRIPTION OF THE DRAWING

These and other benefits and advantages of the novel mobile structuralunit molding and assembling apparatus and method of the presentinvention will be apparent from the following description and theaccompanying drawings in which:

FIG. 1 is a view in perspective of one form of mobile structural unitmolding and assembling apparatus of the invention in use;

FIG. 2 is an enlarged fragmentary side view partially in section of themolding and assembling apparatus shown in FIG. 1;

FIG. 3 is a reduced top view of the molding and assembling apparatusshown in FIG. 1;

FIG. 4 is a schematic illustration of a side view of the apparatus ofthe invention assembling an upper tier of structural units; and

FIG. 5 is a top view of assembled structural units of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in the drawings, one form of mobile structural unit molding andassembling apparatus 11 of the present invention includes a supportportion 13, a raw material supplying portion 14, a molding portion 15, aunit transferring portion 16 and a control portion 17.

The support portion 13 of the molding and assembling apparatus 11 of theinvention includes at least one base section 20. Carriage means 21depending from base section 20 includes at least one transverse axleassembly 22, and advantageously more than one axle assembly shown asaxle assemblies 22 and 23. Wheels 24 and 25 are mounted on free ends ofeach axle.

The raw material supplying portion 14 of the molding and assemblingapparatus 11 includes a plurality of reservoirs 27, 28, 29 and 30disposed on the base section 20. These reservoirs may include storagechambers for resin forming materials, fillers, reinforcements, colors,catalysts, foam forming materials, other additives, premixed inertmixtures thereof and the like.

The molding portion 15 of the apparatus 11 of the invention includes atleast one rotatable mold assembly 32 disposed on the base section. Themold assembly 32 includes at least two separable mold sections andadvantageously a plurality of mold sections shown as sections 33, 34, 35and 36.

The molding portion 15 also includes a mixing chamber 38. The mixingchamber 38 is disposed adjacent the mold assembly 32 and preferablyclosely adjacent thereto. The mixing chamber 38 is connected with theraw materials reservoirs 27-30 through independent conduit means 39 (oneof which is shown in FIG. 3). Preferably, separate bypass return conduitmeans 40 (one of which is shown) extend from one end of each conduitadjacent the mixing chamber 38 back to the respective reservoir.

The molding portion 15 advantageously includes a frame assembly 42 toeffect rotation of mold assembly 32 about more than one axis. The frameassembly preferably includes parallel upstanding end sections 43 and 44with a plurality of independently rotatable frame members shown asframes 46, 47 and 48 extending therebetween. Each frame member includesa large open central area 49. Each inner frame member is progressivelysmaller in size and is disposed within an open central area of the nextlarger frame member.

Alternate frame members 46 and 48 advantageously as shown are rotatableabout aligned axes 51 and 53. The frame member 47 therebetween isrotatable about an axis 52 generally perpendicular to the aligned axes51 and 53. The smaller frame members generally are centered within theopen central area of the next larger frame member, that is, frame 48inside 47 and frame 47 inside 46.

The frame members preferably are of a generally multiangularconfiguration. The frame members advantageously are formed of tubing,most preferably with a quadrangular, e.g. square cross section. It isdesirable for the raw material conduits and the electrical conductorsenergizing frame drive means to be disposed along the frame members.

The unit transferring portion 16 of the molding and assembling apparatus11 of the present invention advantageously includes movable conveyingmeans 55, preferably including endless belts 56. Advantageously, theunit transferring portion includes a plurality of conveying sections 57,58 and 59 arranged in a generally end-to-end relationship. The conveyingsections 57-59 preferably form a substantially continuous path from themolding portion 15 to a unit placement position 60.

The movable conveying means 55 advantageously includes an end 62adjacent the molding portion 15 that is movable from a position spacedfrom the mold assembly 32 during rotation thereof to a position closelyadjacent to the mold assembly when rotation thereof ceases. Thus, asshown in FIG. 2 of the drawings, end 62 of conveying section 57 whichpivots about point 63 is disposed in a lowered position during rotationof the mold assembly and is moved to a raised position with piston 56when rotation ceases and pivotable mold section 36 is lowered.Separating end mold sections 33 and 35 allows a freshly moldedstructural unit 64 to drop onto the raised end of conveying section 57.

The unit transferring portion 16 of the molding and assembling apparatus11 includes a tiltable unit positioning assembly shown as conveyingsection 59. The unit positioning assembly is selectively movable withrespect to the molding portion 15.

The tiltable unit positioning assembly (section 59) which is remote fromthe molding portion advantageously includes extending means shown aspiston 65 and elevating means 66 shown as chain 67 and sprockets 68, 69.Adjacent ends 71, 72 and 73, 74 of the conveying sections 57, 58 and 59preferably are maintained in close proximity through suitable means suchas pistons 76, 77 and 78. It is desirable that the unit transferringportion 16 be pivotable with respect to support portion 13 about point79.

The control portion 17 of the molding and assembling apparatus 11 of theinvention includes programmable memory means 81, coordinating means 82,sensing means 83, actuating means 84, multi-axis mold rotating means 85,unit orienting means 86 and appropriate circuitry interconnecting same.The coordinating means 82 preferably automatically controls the unitmolding and assembly operations.

The sensing means 83 advantageously may include a laser beam generator88 directed along a line on which the units are being assembled.Receivers 89 and 90 may be located adjacent each end of the tiltingconveying section 59 to sense when the unit moving on the conveyor is ina correct orientation for positioning and assembly with other units.

The control portion 17 of the apparatus 11 also includes a plurality ofpumps, valves, monitors and the like. Advantageously, a pump, a valveand a flow monitor are located along the length of each conduit 39 thatextends between the raw material reservoirs 27-30 and the mixing chamber38.

In addition, the control portion includes a plurality of drive means(not shown). Drives provide independent rotation of each frame member46-48. Other drives provide separation of the mold sections 33-36.

Advantageously, the coordinating means 82 includes a process controllerthat initiates changes in the flows of materials and speeds of drives tobring variations therein back to the rates specified in the programspresent in the memory 81. This coordination commonly is achieved throughthe transmission of information such as digital pulses from the monitorsand/or sensors at the control components to the process controller. Theoperating information is compared with the preselected programmingparameters stored in the memory. If differences are detected,instructions from the controller change the operation of the componentsto restore the molding operation to the preselected processingspecifications.

Novel molded structural units may be formed continuously using themolding and assembling apparatus 11 shown in the drawings employing thefollowing steps of the molding and assembling method of the invention.With the design of the desired unit and the location of the mateableperipheral sections thereof established, the control portion 17including memory 81 which may be a computer, is programmed with thenecessary processing parameters for the particular unit being molded andthe structure being formed therewith.

The apparatus 11 is moved to a location at which the preselectedstructure is to be formed and generally aligned alongside the positionof one wall. Then, the laser beam generator 88 is focused along the lineof the wall to be constructed.

To begin the operation of the apparatus 11, buttons and/or switches (notshown) are depressed to activate the memory 81 and the other componentsof the control portion 17. The coordinating means 82 energizes drives tolock the mold sections together and the drives for rotation of eachframe member 46-48.

Also, the pumps, the valves and the flow monitors (not shown) areenergized by the coordinating means 82 in the preselected sequences ofthe program stored in the memory. This causes the raw materials inreservoirs 27-30 to advance along the conduits 39 toward the mixingchamber 38. For example, to mold a product including a foamedpolyurethane resin, reservoir 27 may contain a previously preparedmixture of an isocyanate and gravel as a particutate filler, reservoir28 a polyol, 29 foam forming materials and 30 and other reservoirs (notshown)--colors, catalysts, etc. as required.

For the production of a high quality molded structural unit of theinvention, it is important that the raw materials delivered to themixing chamber be uniform in volume and composition. This can befacilitated by providing a continuous flow of raw materials to themixing chamber 38 and the immediate transfer of the mixture therefrominto the mold cavity. However, the volume of the mixture delivered intothe mold cavity will vary depending upon the particular incremental areaof the cavity being coated at any instant. Also, the delivery will beterminated completely when a molded unit 64 is being removed from themold assembly 32.

Advantageosly, as shown in FIG. 3, a separate bypass conduit 40 isutilized from the end of each conduit 39 at a point adjacent the mixingchamber 38 back to the respective reservoir 27-30. This constructionprovides a freshly formed uniform mixture into the mold cavity eventhough the distance is considerable between the reservoirs and themixing chamber which is located closely adjacent or even within the moldassembly 32.

The control portion 17 coordinates the operation of the various systemcomponents so the required formulation can flow into the desired zoneswithin the rotating mold cavity. After the desired volume of the mixturehas passed into the mold cavity, rotation of the frame members 46-48 iscontinued to flow the mixture over all surfaces of the mold cavity in apreselected and monitored rotational profile.

The rotations are controlled within the parameters stored in the memory81. For particular structural units, the rotations about the respectiveaxes may be continuous and/or intermittent at changing rates. Also, itmay be desirable to provide arcuate rotation, that is, movement about anarch such as a rocking motion.

The components of the liquid mixture that flow into the mold cavityquickly begin to react to form a thermosetting resin structure whilerotational movement of the mold assembly 32 continues about severalaxes. The mixture initially spread over the mold interior forms a resinstructure with a high density and with little or no bubble formation.This dense structure includes primary structural components of thestructural unit, that is, face sections, frame sections, connectormembers, etc. and usually a thin shell on other portions of the unitbeing molded. It is customary, however, to add to the mold cavity asecond formulation that includes a significant proportion of afoam-forming ingredient to form a less dense resin foam within theremaining areas of the unit.

To provide structural units of the invention which are receptive toenvironmental conditions such as light, heat, cold, etc., transparentand translucent panels and other components can be formed during themolding either prior to, simultaneously with or subsequent to theformation of the primary structural components discussed above.

When all of the desired parts of the unit have been molded, rotation ofthe mold assembly 32 is stopped, the mold section 36 lowered and end 62of conveying section 57 is raised close to the molded unit 64. Then,mold sections 33-35 are separated allowing the unit to drop onto theconveyor 57.

As the end 62 of conveyor 57 is being raised with piston 56, elevatingmeans 66 is raising or lowering conveyor 59 into an appropriate positionto assemble the next molded unit. Simultaneously, pistons 76 and 77 moveconveyor ends 71, 72 and 73, 74 into proper elevation to provide acontinuous path for the movement of the freshly molded unit alongconveyors 57, 58 and onto tiltable positioning conveyor 59.

When the structural unit reaches the conveyor 59, pistons 65 and 78 andorienting means 86 associated with the unit positioning assembly areactivated to move the unit into position for assembly with other units92. As inclined unit 91 interrupts a lower beam being emitted fromsensing means 83, this information is transmitted to memory 81. Movementof the unit 91 is continued until receiver 90 becomes aligned with thelower beam. At this point, the lowest edge of the inclined unit 91 isoriented with the corresponding edge of adjoining unit 92 for assemblytherewith.

Piston 78 then raises conveyor 59 and unit 91 thereon into a morevertical position. Raising of conveyor 59 causes the unit to break thebeam from upper generator 88 and movement is continued until receiver 89is aligned with the upper beam. The unit 91 now is tightly assembled tounits 92. The unit positioning assembly including conveyor 59 then iswithdrawn by the reversal of piston 65 to receive each succeedingstructural unit 64 advancing along conveyors 57 and 58. The molding andassembling steps are repeated on a continuing basis to form a structure.

FIG. 4 illustrates the disposition of conveyors 57 and 58 to facilitateassembly of an upper tier of units on top of previously positionedunits. As shown, conveyors 57 and 58 moved a molded unit upwardly from amolding assembly (not shown) to conveyor 59 which has been moved to araised position by elevating means such as 66 shown in the otherfigures.

FIG. 5 illustrates a fragmentary assembly of structural units viewedfrom above. As shown, the edges of the units are sculptured to permitleft to right assembly of each unit in close engagement with unitpreviously positioned. The particular edge configuration will bedependent upon the specific use of the structural units. If desired, aresilient spacing material may be inserted between adjacent structuralunits during assembly. Such spacing may be appropriate when the mass ofeach structural unit is large and considerable temperature variationsare anticipated in service.

With the configuration shown in FIG. 5, a vertical passage 94 is formedbetween adjacent units. A reinforcing beam or rod 95 may be insertedalong the passage. In FIG. 4, a reinforcing rod 97 has been insertedinto a horizontal opening 96 between units prior to tilting unit 93 intoa vertical position aligned with units 92. Intersecting rods betweenunits may be joined to form an integral reinforcing network if desired.Alternatively, or in addition, passages 94 and 96 may be filled with aresin forming material similar to that employed in the molding of theunits.

The structural unit 64 leaving mold assembly 32 has structural integrityand is not fully cured. Advantageously, edges of each unit are adhesive.Curing of the unit continues as the unit moves along the conveyors andis assembled with other units to form the desired structure. During thisperiod, the final expansion of the unit, free of the mold's restraint,stresses the high density outer skin or layer of the unit. Thisstressing of the skin increases the strength and puncture resistancethereof and also the structural strength of the unit itself.

The structural strength of the unit can be enhanced further by includinga reinforcement such as metal or fiberglass fibers in the mixture priorto molding. Also, preformed reinforcements such as metal rods can bepositioned in the mold cavity before the mold sections are closed.

Other properties of the structural unit may be modified by selectivechoice of raw materials and components. For example, heat and/orcombusion resistance may be improved by the use of phenolic resinforming materials. Also, the appearance and texture of the majorsurfaces of the structural units can be chosen to simulate smooth orrough wood, split shakes, stone, tile, etc. as well as original designs,murals and the like.

The molding and assembling apparatus and method of the invention can bemodified to accommodate particular structural units, assemblyrequirements and erection sites. The various portions of the apparatuscan be separated or consolidated as required.

The above description and the accompanying drawings show that thepresent invention provides a novel structural unit molding andassembling apparatus and method with features and advantages notpreviously available. The molding and assembling operations areintegrated to provide a high degree of design flexibility andconstruction efficiencies.

The molding and assembling are accomplished automatically with a minimumof hand labor. The method and apparatus can be adapted to mold andassemble the wide variety of structural units required and desired toconstruct buildings and other structures of many different designs.

The apparatus and method of the invention accomplished above withoutsacrificing uniformity of dimensions, composition and quality. Theapparatus can be manufactured with readily available materials andcomponents employing conventional fabricating techniques.

It will be apparent that various modifications can be made in theparticular apparatus, method and product described in detail and shownin the drawings within the scope of the present invention. The size,configuration and arrangement of components of the apparatus and productcan be changed to meeet specific requirements. Also, raw materials andmethod steps can be added or eliminated as required.

These and other changes can be made in the method, apparatus and productof the invention provided the operation and functioning thereof are notadversely affected. Therefore, the scope of the present invention is tobe limited only by the following claims.

What is claimed is:
 1. A method of continuously molding and assemblingstructural units including the steps of providing a plurality of rawmaterial reservoirs, continuously moving raw materials from saidreservoirs independently to a mixing chamber located adjacent to arotatable mold assembly including separable mold sections, introducingsaid raw materials into said mixing chamber, passing a freshly formedmixture flowing from said mixing chamber directly into a cavity of saidmold assembly, rotating said mold assembly about more than one axis,flowing said mixture over all surfaces of said mold cavity by saidrotation, continuing said rotation of said mold assembly while saidmixture forms a structural unit within said cavity thereof, monitoringthe delivery of raw materials to said mixing chamber, the resultingmixture flowing therefrom and the multiple axis rotation of said moldassembly, separating said mold sections of said mold assembly, removinga molded structural unit from said separated mold sections, transferringsaid unit along a substantially continuous conveying surface to apreselected position remote from said mold assembly while said unitpossesses structural integrity and is not fully cured and while edgesthereof are adhesive, orienting said unit in an inclined orientation,sensing when a leading edge of said unit is properly located forassembly and moving said unit into a preselected final orientationassembled with previously positioned units and repeating the above stepson a continuing basis to form a structure.
 2. A method of continuouslymolding and assembling structural units according to claim 1 includingcoordinating and controlling the steps of the method automatically.
 3. Amethod of continuously molding and assembling structural units accordingto claim 1 including rotating said mold assembly about multiple axesalternately generally perpendicular to one another.
 4. A method ofcontinuously molding and assembling structural units according to claim1 including introducing a resin forming component into said mixingchamber.
 5. A method of continuously molding and assembling structuralunits according to claim 4 including introducing a thermosetting resinforming component into said mixing chamber.
 6. A method of continuouslymolding and assembling structural units according to claim 4 includingintroducing a phenolic resin forming component into said mixing chamber.7. A method of continuously molding and assembling structural unitsaccording to claim 1 including introducing a particulate filler intosaid mixing chamber.
 8. A method of continuously molding and assemblingstructural units according to claim 1 including introducing areinforcement into said mixture prior to molding.
 9. A method ofcontinuously molding and assembling structural units according to claim1 including introducing a foam forming component into said mixingchamber.
 10. A method of continuously molding and assembling structuralunits according to claim 1 including placing a resilient spacingmaterial between adjacent structural units during assembly.
 11. A methodof continuously molding and assembling structural units according toclaim 1 including placing preformed beams within passages through saidassembled units during assembly.
 12. A method of continuously moldingand assembling structural units according to claim 1 includingintroducing a freshly formed flowable mixture into passages through saidassemled units during assembly.